3D Printer Head Yaw Angle Adjustment for Nozzle Clogging Detection
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Solution Overview
Problem
Three-dimensional object printing apparatuses using ink jet methods face issues with nozzle clogging, leading to deteriorated image quality due to the lack of effective maintenance and detection mechanisms for nozzle defects during the printing process.
Innovation Solution
A three-dimensional object printing apparatus and method that incorporates a robot with rotating portions to change the position of a head with a nozzle row, performing a first printing operation on a three-dimensional medium and a second printing operation on a test pattern medium with different yaw angles, allowing for detection and prevention of nozzle clogging through a maintenance unit that includes a cap, wiper, and inspection mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a robot arm with print head is used for three-dimensional object printing, then printing capability on complex surfaces is improved, but nozzle clogging occurs leading to deteriorated image quality
Solution Approach 1:
The system performs a test pattern printing operation before the actual three-dimensional object printing to detect nozzle clogging in advance. The robot arm prints a test pattern on a flat medium, and the imaging device captures the result to identify any defective nozzles. This preliminary detection allows the system to prevent deteriorated image quality in the main printing operation by detecting nozzle issues before they affect the actual workpiece.
Solution Approach 2:
The system uses an imaging device to capture images of the test pattern and provides feedback to the control device. The control device analyzes the captured image to determine whether nozzle clogging has occurred, and based on this feedback, decides whether to proceed with the main printing operation or perform maintenance on the print head. This closed-loop feedback mechanism ensures reliable image quality by continuously monitoring nozzle performance.
2Measurement precision
If nozzle inspection is performed during printing operations, then detection accuracy is improved, but printing productivity decreases
Solution Approach 1:
The nozzle inspection is performed as a preliminary action before the main three-dimensional object printing operation, not during it. The robot arm first prints a test pattern on a flat medium, the imaging device captures and analyzes the pattern to detect nozzle clogging, and only after this inspection is complete does the system proceed to the actual printing work. This separation of inspection and production maintains high printing productivity while achieving accurate nozzle defect detection.
3Measurement precision
If the head position is changed for test pattern printing, then nozzle clogging detection accuracy is improved, but device complexity increases
Solution Approach 1:
The robot arm and print head assembly serve multiple functions: they perform both the test pattern printing operation and the main three-dimensional object printing operation. The same imaging device is used to capture both test patterns and potential workpiece images. By making these components multi-functional, the system achieves accurate nozzle clogging detection through position changes without significantly increasing device complexity, as the existing hardware is utilized more flexibly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents deteriorated image quality by detecting and resolving nozzle clogging issues before the main printing operation, ensuring consistent and high-quality prints by integrating a test pattern printing mechanism within the apparatus.
Implementation Method 1
a head (3a) having a nozzle surface (F) provided with a nozzle row (La, Lb) in which a plurality of nozzles (N) for ejecting an ink are arranged
Data Source
AI summary
A three-dimensional object printing apparatus includes: a head having a nozzle surface; and a robot that has a base portion and an arm portion that supports the head, and changes a position of the head with respect to the base portion, in which the three-dimensional object printing apparatus is configured to execute: a first printing operation of causing the head to print an image to a three-dimensional first medium, and a second printing operation of causing the head to print a test pattern while causing the robot to change a position of the head with respect to the second medium, and a yaw angle of the head during the execution of the first printing operation and a yaw angle of the head during the execution of the second printing operation are different from each other.